Footwear

ABSTRACT

A footwear comprises a sole provided with a foamed inner layer therein and a non-foamy outer layer integrally surrounding said foamed inner layer, a shape preservative fixture for an instep cover member being protruded integrally from the required edge portion of said sole, the foamed inner layer and non-foamy outer layer of said fixture being respectively and integrally connected with the foamed inner layer and non-foamy outer layer of the sole and the fitting portion of the instep cover member being affixed removably or firmly to the shape preservative fixture.

United States Patent Fukuoka [54] FOOTWEAR [72] Inventor: TatsuoFukuoka, 3,3-Ban, 2-chome,

Shin-Minami, Tokushima, Japan l l Filed: Feb. 12, 1971 1 App]. No.:114,844

[30] Foreign Application Priority Data Oct. 19, 1970 Japan ..45/10405ONov. 12, 1970 Japan ..45/1 12294 [52] US. Cl ..36/11.5 [51] Int. Cl...A43 b 3/12 [58] Field of Search .....36/2.5 R, 11.5

[56] References Cited UNITED STATES PATENTS 2,507,120 5/1950 Shapiro...36/ll.5

1 Oct. 17,1972

5/1956 l/l97l Gerber ..36/l 1.5 Fukuoka ..36/l 1.5

Primary ExaminerPatrick D. Lawson Attorney-Dawson, Tilton, Fallon &Lungmus [57] ABSTRACT A footwear comprises a sole provided with a foamedinner layer therein and a non-foamy outer layer integrally surroundingsaid foamed inner layer, a shape preservative fixture for an instepcover member being protruded integrally from the required edge portionof said sole, the foamed inner layer and non-foamy outer layer of saidfixture being respectively and integrally connected with thefoamed-inner layer and non-foamy outerlayer of the sole and the fittingportion of the instep cover member being affixed removably or firmly tothe shape preservative fixture.

9 Claims, 25 Drawing Figures PATENTEBnm 1 1 2 3 698, 1 01 SHEET 010F15PATENTEDncI 11 I972 SHEET D20F15 PATENTEDum 11 I972 3. 698, 107 SHEETcuuf 15 PATENTEDBIIHYIQTZ 3.698.107

SHEET USUF 15 PATENTEflum 1 1 I972 SHEET as [If 15 PATENIEDnm 11 I972SHEET [NW 15 FIG/2 PATENTEDncI 1 1 I972 SHEET UBUF 15 F/GJJ FIG/4PAIENTEMN 1 I9 2 3.698.107

SHEET llUF 15 FIG. n9

PATENTEMN H 1912 3.698.107 SHEET 12M 15 FOOTWEAR The present inventionrelates to afootwear and especially the footwear provided with a shapepreservative fixture for an instep cover member being protrudedintegrally from a sole, the fitting portion of said instep cover memberbeing affixed removably or firmly to said shape preservative fixture.

It was disclosed in the Japanese Utility Model Publication No. 18549/69a technique for producing sturdy and light weight yet extremelycomfortable-to-wear sandal integrally molded and formed withthermosetting synthetic resin material in about one operation and in avery short time, however, as to this kind of sandals and conventionalshoes and other footwears, it was impossible to have such kind of instepcovering member like bands, strips, straps and others which comprisewith the wearers high class taste and to provide therewith variousdesigns, to the same sole member. s i

And, the aforesaid shortcomings are owing to an evil of mass production.However, it is difficult to obtain footwears applied with variousdesigns, that is, handmade high class footwears by mass production, and,even in case an improved mass producing method is adapted, if a numberof hand works are included in the process, it rather raises theproduction costs and retail prices of the finished goods, which forcesthe general consumers unnecessary expenditure as a result.

The inventor has had several hard works to solve the above-mentionedproblem and, as a result, has succeeded in developing the inventedfootwears after experiencing many failures.

The invented footwears, although are possible to be manufactured by massproduction, are given varieties thereupon, and the instep coveringmembers thereof are representable of casual-like and other variousdesigns in order to express the wearers individuality and other highclass designs suitable for high quality footwears. Further, theconsolidated state between the instep covering member and the sole isbeing made more sturdy thereby the instep covering member isundetachable from the sole even after along use of the footwear.Further, the instep covering member is freely selective against a soleto which it is to be attached in the process of the production of thefootwears, and the scope of selection can be extremely enlargenedhThatis, a variety of the instep covering members, all different in theirdesigns, shapes, constructions and others are being prepared which areoptionally attachable to the soles in accordance with the objectsthereof.

To sum up, in conventional sandals, shoes and other footwears,particularly in footwears wherein the instep covering members such asbands, straps and others are integrally molded with the footwears sole,it was not possible to have a more tough material of instep coveringmembers such as bands, straps and others as against that of soles, or tohave instep covering members rich of designs, or to have them inexpensive materials such as natural leather and others, or to have themin socalled separate style with buckles attached to the instep coveringmembers. However, the invented footwears are completely fulfilling theafore-mentioned requirements.

Specially, it is difficult to harmonize design-wise a naturally designlacking and monotonous sole with instep cover member having remarkabledesign, however, in the instance of the invented footwears it ispossible to harmonize design-wise the instep cover member havingremarkable design with the sole due to the interposition of the shapepreservative fixture incorporated with the sole and to whichthe instepcover member is being attached, particularly, due to the interpositionof this shape preservative fixture intermediately between the sole andthe instep cover member and which form having been constructed so as tosuit the instep cover member. Further, this shape preservative fixtureitself is capable of providing designing effects to the footwearsdepending on the forms and others of the fixture. Furthermore, in caseof the invented footwears, the connecting portion of sole and instepcover member is being placed at a higher position as compared to that ofthe conventional footwears. This is because the instep cover member isnot directly attached to the sole but because the shape preservativefixture is being interposed between the sole and the instep covermember. Therefore, usually in footwears the connecting portion is easilyspoiled due to submersion or other reasons, thus the defect such asdetachment of instep cover member from sole will occur, but in case ofthe invented footwears, since the connecting portion is being placed ata higher position than that of the conventional footwears, the spoilingdegree due to submersion and other reasons is greatly reduced whichmeans a prevention of dissociation of the connecting portion.

And, in sandals which construction was to secure both ends of the bandsdirectly to the soles, there was an important defect wherein bandseasily detached from soles as the connecting portion between bands andsoles was constantly bearing a load and, particularly when users staggerwhen walking, a sudden shock was given to this portion which resulted indisconnection of bands from soles. This was the same in shoes, thereforeit was especially necessary to reinforce the connecting portion betweeninstep cover and sole. However, in case of the invented footwears, theinstep cover members such as bands and straps are being fitted to thesoles by means of the shape preservative fixture, therefore naturallythe position where the cover member is attached to the sole isrelatively high and users load and shock will not be given to theconnecting portion of the instep cover member and sole but to the shapepreservative fixture embodied with the sole. Another reason for avoidingthe load and shock by the connecting portion is the construction of thefootwear wherein the shape preservative fixture is being builtintegrally from the sole of which the inside is formed of foamed innerlayer and outside of nonfoamy outer layer and, while inside of thisshape preservative fixture is formed of foamed inner layer integrallywith the aforesaid foamed inner layer of the sole, the outside of thefixture is formed of non-foamy outer layer integrally with the non-foamyouter layer of the sole.

The shape preservative fixture integrally formed with the sole can wellwithstand not only a load but a sudden shock however big it can be. Thatis, because of the intervention of the foamed inner layer inside theshape preservative fixture, the fixture functions so as to enableelastically the shock absorption and, since the foamed inner layerinside the shape preservative fixture is integrally formed with thefoamed inner layer inside the sole, the shock added to the shapepreservative fixture will be scattered about throughout the sole due tothe existence of the integrally formed ventilating foamed inner layerinside thereof.

In this way, the shape preservative fixture is being made so as toconstantly and mainly receive the load and shock, is functioned so as toscatter about the shock, eventually the entire sole will receive theshock or load and, since the entire sole is being integrally molded in aconstruction of foamed inner layer and non-foamy outer layer, the shapepreservative fixture and sole of the invented footwears are fullyensured of durability and shock-proof thereof. Further, even after along use, the integrally intervening non-foamy outer layer outside thesurface of the shape preservative fixture and the sole is protecting thefoamed inner layer from deformation and this shape preservative effectis also ensured due to the integration of the foamed inner layer andnon-foamy outer layer. For instance, when a shock is added tothe shapepreservative fixture, the shape preservative fixture and the sole willbe deformed on account of scatter of the shock, however after the shockis gone, the non-foamy outer layer will function well enough to restorethe original forms of the shape preservative fixture and the sole. Inother words, dual effects of the shape preservation, that is, theresilient deformation of the foamed layers of the shape preservativefixture and the sole, and the restoration of the original form by thenon-foamy layer integrated with the foamy layer are organicallyperformed for obtaining shock-proof.

Particularly, the technique of fitting the instep cover members such asbands, straps and others in a required form (a form to provide the usera better comfort-towear and a nice external appearance) to the sole andmaintaining this preferred form in the instep cover member after beingfitted to the sole is considered to be difficult, therefore, a specialproducing mold and other special appliances were conventionallynecessitated in the process of manufacturing sandals and shoes. However,the said invention does not require the use of any such specialappliances as mentioned above for attaching the comfortable-to-wear andnice looking instep cover member very easily to the sole and maintainingthis ideal shape in the instep cover member after production andspecially for a long time use thereafter. This is because the instepcover member of the invented footwears is not attached directly to thesole. That is, the instep cover member is-attached to the sole by meansof the shape preservative fixture built integrally with and from thesole and, since this shape preservative fixture is integrally moldedsimultaneously with the integral formation of the sole in the mold, theshape preservative fixture itself is always formed definitely in therequired form and the form of the instep cover member is controllable inaccordance with the form of the shape preservative fixture at the timeof attachment as the instep cover member is attached to the shapepreservative fixture which is shaped exactly in the desired form.Further, after the instep cover member is attached indirectly to thesole in the exactly desired form, even if the instep cover member istend to change the required shape thereof after a long use or due toshock, the said shape preservative fixture will not allow suchdeformation.

This can be understood by the fact that the instep cover members such asbands, straps and others are attached to the soles by means of the shapepreservative fixtures through the method for indirect attachment asagainst the method for direct attachment wherein in-- step cover membersare being directly attached to soles, so that form adjustment and othersare favorably allowable during work of the fixtures in order to providethe instep cover members the desired form, a comfort to-wear andpreferred external appearance as against the soles of desired form.

Furthermore, since the non-foamy outer layer existing in the outersurface of the shape preservative fixture is always performing shapepreserving effect in cooperation with the material thereof, it showsdefinitely the functions thereof in the event of deformation preventionof the instep cover members.

In addition, on account of the imposition of the shape preservativefixture between the sole and the instep cover member, it is possible toreduce the material of the instep cover member equivalent to the area ofthe shape preservative fixture. This has a specially important meaningwhen an expensive natural leather is being used for the instep covermember.

The invented sole is integrally molded with thermosetting syntheticresins material. And the inner portion of the sole is vesicated by meansof the required vesicant molding means either containing or notcontaining vesicant thus forming a foamed inner layer, the visible orinvisible non-foamy outer layer being formed continuously with the saidfoamed layer is further formed, and the cross-sectional view of thisvesicated foamy layer shows that the average particle diameter of thebubbles is successively growing larger from the surface towards thecenter throughout the non-foamy outer layer and the foamed layer. Insome cases, though, the average particle diameter of the bubbles is notsuccessively growing larger. The users sole contacting surface of theabove mentioned sole is providing an uneven shape in order to closelyconform to the profile of the users sole.

Furthermore, the shape preservative fixtures are formed integrally in anupward protruding shape from the required edge of the sole. Therefore,the inner construction of the shape preservative fixture is completelyidentical with that of the aforesaid sole and is possessing the foamedand non-foamy layers continuously constructed with the foamed andnon-foamy layers of the aforesaid sole. The instep cover member isconstituted either absolutely of ventilative basic material or of thebasic material combined with the designing material and the instep covermember is attached to the sole by means of the shape preservativefixture easily removably or firmly.

The following is the explanation of the subject invention according tothe embodiments referred to in the attached drawings wherein:

FIG. 1 is a perspective view of the first Embodiment of the inventedfootwear;

FIG. 2 is a cross-sectional view of FIG. 1 taken along the line II-II;

FIG. 3 is a cross-sectional view of the second Embodiment of theinvented footwear;

FIG. 4 is a perspective view of the third Embodiment of the inventedfootwear;

FIG. 5 is a perspective view of the fourth Embodiment of the inventedfootwear;

FIG. 6 is a perspective view of the fifth Embodiment of the inventedfootwear;

FIG. 7 is a longitudinal sectional view of the forming mold of thefootwear shown in FIG. 4;

FIG. 8 is a cross-sectional views of the mold shown in FIG. 7;

FIG. 9 is a perspective view of the sixth Embodiment of the inventedfootwear;

FIG. 10 is a perspective view of the seventh Embodiment of the inventedfootwear;

FIG. 1 l is a cross-sectional view of FIG. 9 taken along the line XI-XI;

FIG. 12 is a cross-sectional view of the eighth Embodiment of theinvented footwear;

FIG. 13 is a perspective view of the ninth Embodiment of the inventedfootwear;

FIG. 14 is a cross-sectional view of the bodiment of the inventedfootwear;

FIG, 15 is a cross-sectional view of the eleventh Embodiment of theinvented footwear;

FIG. 16 is a cross-sectional view of the twelfth Embodiment of theinvented footwear;

FIG. 17 is a perspective view of the thirteenth Embodiment of theinvented footwear;

FIG. 18 is a perspective view of the fourteenth Embodiment of theinvented footwear;

FIG. 19 is a cross-sectional view of the eleventh Embodiment of theinvented footwear;

FIG. 20 is a cross-sectional view of the twelfth Embodiment of theinvented footwear;

FIG. 21 is a perspective view of the thirteenth Embodiment of theinvented footwear;

FIG. 22 is a perspective view of the fourteenth Embodiment of theinvented footwear;

FIG. 23 is a cross-sectional view of the fifteenth Embodiment of theinvented footwear;

FIG. 24 is a plane view of the sixteenth Embodiment of the inventedfootwear in which main portion of the instep cover member is cut off;and

FIG. 25 is a cross-sectional view of the seventeenth Embodiment of theinvented footwear.

tenth Em- Embodiment 1 Sole la of the sandal shown in FIGS. 1 and 2 isbeing integrally molded with thermosetting synthetic resin material.This material is a mixture of, for instance, vinyl chloride,plasticizer, vesicant, stabilizer, lubricating material, coloring agentand others which is being molded by means of injection molding machine.There are several kinds of these molding methods, for instance, themethod shown in the U8. Letters Pat. No. 3058161. As to the manufactureof the invented footwears, reference is made to the method shown in theJapanese Pat. Pub. No. 22213/64. The inner composition of thus foaminglymolded sole 1a is constituted of foamed inner layer 2a and non-foamyouter layer 3a. This foamed layer 2a is possessing a construction in itscross-section wherein the average particle diameter of the bubbles issuccessively growing larger from the surface towards the center of thefoamed layer. And this inner foamed layer 2a and the visible orinvisible nonfoamy outer layer 3a of the surface layer surrounding theinner foamed layer are continuously constructed,

and these are obviously distinguishable or indistinguishable from theexternal appearance thereof. Further, the non-foamy outer layer is insome cases in a state of thin film hard to be called a layer. Thesurface of the sole 1a, that is, the userssole contacting surface ispossessing a shape in order to closely or somewhat conform to theprofile of the users sole. The peripheral edge portion a of the sole isbeing raised all the way, the approximate center b of the heel is beingrecessed generously from this raised portion of the peripheral edge,this recession "b is being continued from the approximate center of theheel up to the recessed toe portion c which is comparatively large andbeing recessed generously from the raised portion of the peripheral edgethrough the comparatively slender recessed channel d positioned slightlyoff the central portion, the shank portion e being raised generouslyfrom the aforesaid recessed channel d in combination with the raisedportion of the peripheral edge and these raised portions and recessionsare being integrally connected by means of a generously undulatedsurface. Furthermore, from the required edge portion of the sole la arebeing built upward one or more required numbers of shape preservativefixtures 4a and, since these are being built integrally from and withthe sole, the inner composition of the shape preservative fixture isexactly the same as that of the sole and the foamed and non-foamy layersthereof are also integrally connected to the relative layers of thesole. On the other hand, the instep cover member 8a is being provided byboring many small holes on the basic material thereof as shown in FIGS.1 and 2. The decorative portion 7a is being formed by inserting therequired ornamental material 6 such as twisted, braided and other yarnsto the plurality of small holes 5 from front and back sides, connectingeach small hole with the yam-like ornamental material 6, thus formingthe decorative portion 7a on the front and back sides of the instepcover member 8a by means of optional yarnlike ornamental material.

Also, the basic material of the aforesaid instep cover member 8a can beprovided in mesh wherein the same decorative portion as mentioned abovecan be formed.

Bore the holes 9a to the aforesaid shape preservative fixtures 4a,attach the ends of the instep cover member 8a to the shape preservativefixtures 4a through these holes by means of the binding accessories 10either removably or firmly in compliance with the usage thereof.

Embodiment 2 The footwear shown in FIGS. 3 and 4 is of the samecomposition as that under Embodiment 1 except that the basic material ofthe instep cover member 8b is possessing the foamed inner layer 2'!) andnon-foamy outer layer 3b same as sole 1b. And this foamed layer 2'b andnon-foamy layer 3'b are of completely identical construction with thelayers 2a and 3a mentioned in Embodiment I.

Embodiment 3 FIG. 5 is showing the footwear provided with the sameconstruction as that of the footwear under Embodiment I, provided thatthe instep cover member thereof 8c provides its unique constructiondiffered from that as shown in FIG. 1.

Embodiment 4 FIG. 6 is showing the footwear provided with the sameconstruction as that of the footwear under Embodiment 2. However in thiscase, the instep cover member is being attached to the shapepreservative fixture by means of buckle so as to afford the users easywearing and taking off.

Explanation is given herewith as to the mold for manufacturing thefootwear shown in FIG. 1 by referring to FIGS. 7 and 8. Numeral 11 isthemold, numeral 12 is the back-and-forth movable core mold, numeral 13is the up-and-down movable mold to enlarge or vary the capacity insidethe cavity 14 at the time of vesicating and numeral 15 is the materialinjecting passage.

Embodiment 5 The sole 16a of the footwear (shoes in this instance) shownin FIGS. 9 and 11 is being integrally molded of thermosetting syntheticresins material. This molding method is exactly the same as in the caseof Embodiment l which is also shown, for instance, in the US. LettersPat. No. 3058161.

This sole 16a is being provided with the foamed inner layer 17a is beingprovided with the foamed inner layer 17a and non-foamy outer layer 18aidentical with Embodiment l and the point relative to the continuouscomposition of the average particle diameter of the bubbles is also thesame as in Embodiment I.

The surface namely the users sole contacting surface of this sole 16a isbeing formed completely identical with that in case of Embodiment I.Further, like in case of Embodiment I, the shape preservative fixture19a is being built upward from the required elevated edge portion of thesole. The instep cover member 20a that is, the instep strap is beingprovided with the reinforc ing portions 21a and 220 at its toe coverportion and heel cover portion respectively, and each of the reinforcingportion is being formed of tough materials such as natural leather,synthetic leather, strong cloth material, hard synthetic resinousmaterial and others. The basic material being used for the instep covermiddle portion 23a existing between the two reinforcing portions 21a and22a is either being bored with a plurality of small holes 24a orprovided with mesh construction. These small holes 24a are beingconnected by means of the required ornamental materials 25a such astwisted yarns, braids and others from front and back sides thus formingthe decorated portion 26a on the front and back surfaces of the basicmaterial of the instep cover middle portion.

' The upper edge portion of the aforesaid shape preservative fixture 19ais being scalloped and a plurality of decorative small pits 27a arebeing provided at this upper edge portion each of them spaced apart fromthe others. A plurality of small pits are being provided at the loweredge portion of the aforesaid instep cover member 20a each of themspaced apart from the others and these small pits are being provided atthe positions corresponding to the small pits so that the lower edgeportion of the member 20a will be connected correctly to the aforesaidshape preservative fixture 1911 at their predetermined connectingpositions when connection is to be made.

The lower edge portion of the aforesaid member 20a is being connected tothe inner side of the aforesaid shape preservative fixture 19a by meansof the aforesaid corresponding small pits at the predeterminedconnecting positions and they are being firmly connected by means ofbinding agent, heat sealing or sewing machine stitching.

Also, there is another case wherein the aforesaid small holes 27a and28a are being substituted with small pits and these corresponding smallholes are being sewn together successively by means of linking materialssuch as strengthened stitching yarn made of strong synthetic resinousmaterial or other suitable materials or others so that the lower edgeportion of the member 20a is firmly connected with the shapepreservative fixture 19a. Bonding agent may also be used in this case toconnect them.

And, usually the shape preservative fixture 19a and the lower edgeportion of the aforesaid member 20a are being connected by stitchingsuccessively the aforesaid corresponding small holes by means of linkingmaterials such as specially tough strengthened stitching yarn andothers, however, it is also possible in this case to attach newlyanother instep cover member preferred by the user to the sole 16a byextracting the former connecting stitched yarn from this connectedportion, replacing the instep cover member 20a being connected to thesole 16a with the new cover member 20a and connecting the lower edgeportion of the new cover member to the shape preservative fixture 19a bymeans of stitching yarn. The aforesaid middle portion 23a is beingformed either integrally with or separately from the two reinforcingportions 21a and 22a, and in the latter case, the middle portion 23a isbeing fixed to the two reinforcing portions removably or firmly by meansof the required connecting means in accordance with the method shown inEmbodiment 6. Numeral 29a in FIG. 11 represents a thin sheet or film.

Embodiment 6 The shoes shown in FIGS. 10 and 12 are being provided withsole 16b, foamed inner layer 17b, non-foamy outer layer 18b shapepreservative fixture 19b, instep cover member 20b, and reinforcingportions 21b and 22b formed completely in the same way as in case ,ofEmbodiment 5. However in this embodiment, unlike in case of Embodiment5, the instep cover middle portion 23b existing in between the tworeinforcing portions 21b and 22b is being formed in the same way as thesole 16b, that is, is possessing foamed inner layer 17'b and non-foamyouter layer l8'b, and the cross section of the foamed layer of the innerportion shows that the average particle diameter of bubbles areconsecutively growing larger from the surface to the central portionthroughout the non-foamy layer and foamed layer. In some cases theparticle diameter is not growing large. This middle portion 23b iseither possessing a plurality of small holes or is being constructed bymesh like basic material. A large number of these small holes are beinglinked from front and back sides by passing through these holes therequired ornamental materials such as twisted yarns, braided yarns andothers thus forming the decorated portion on the front and back sides ofthe middle portion 23b by means of optional ornamental material. Theaforesaid middle portion 23b is being fixed to the two reinforcingportions 21b and 22b either

1. A footwear comprising a sole provided with a foamed inner layer madeof thermoplastic material and a non-foamy outer layer integrallysurrounding said foamed layer, at least one shape preservative fixturefor an instep cover member having a foamed inner layer and a non-foamyouter layer being built integrally with and from the required edgeportion of said sole, the foamed layer and the non-foamy layer of saidfixture being respectively and integrally connected with the foamed andnon-foamy layers of the sole, and the edge portion of the instep covermember being attached to the shape preservative fixture.
 2. A footwearas claimed in claim 1, in which the foamed inner layer has aconstruction in its cross-section wherein the average diameter of thebubbles is successively growing larger from the surface thereof towardsthe center thereof.
 3. A footwear as claimed in claim 1, wherein thesurface of the sole is uneven in comformity with the profile of theuser''s sole.
 4. A footwear as claimed in claim 1, wherein the instepcover member provides a decorative portion consisted of penetratingholes and ornamental material inserted thereinto.
 5. A footwear asclaimed in claim 1, wherein the foamed inner layer and non-foamy outerlayer of the shape preservative fixture are integrally connected to thefoamed inner layer and non-foamy outer layer of the sole, respectively.6. A footwear as claimed in claim 1, wherein the basic material of theinstep cover member is provided with a foamed inner layer and non-foamyouter layer integrally connected to each other.
 7. A footwear as claimedin claim 1, wherein the instep cover member is provided with at least areinforcing portion.
 8. A footwear as claimed in claim 1, wherein thelower edge portion of the instep cover member is connected to inner orouter side of the shape preservative fixture while small pits on saidlower edge portion of the instep cover member face pits of the shapepreservative fixture.
 9. A footwear as claimed in claim 1, wherein smallholes of lower edge portion of the instep cover member face small holesof the shape preservative fixture.